30 RECYCLED PAVEMENT 30-1 GENERAL 30-1.01 GENERAL 30-1.01A Summary Section 30 -1 includes general specifications for constructing recycled pavement bases . 30-1.01B Definitions Reserved 30-1.01C Submittals 30-1.01C(1) General At least 20 days before starting pavement recycling work, submit the QC plan. The QC plan must describe the organization, responsible parties, and procedures you will use to:
1.Perform QC including sampling, testing, and reporting
2.Determine action limi ts if corrective actions are needed
3.Implement corrective actions
4.Ensure pulverizing, compacting, grading, and finishing activities are coordinated The QC plan must include copies of the forms that will be used to provide the required inspection reco rds and sampling and testing results. Forms must show project requirements. The form for recording and reporting the QC measurements must show the proportions of materials used. The QC plan must include a contingency plan that describes the corrective acti ons you will take in the event of equipment break down. The corrective actions must include repairing and reopening the roadway to traffic using minor HMA under section 39. 30-1.01C(2) Asphaltic Emulsion For each dilution of asphaltic emulsion used on the finished recycled pavement surface submit as an informational submittal:
1.Asphaltic emulsion type
2.Weight ratio of water to bituminous material in the original asphaltic emulsion
3.Weight of asphaltic emulsion before diluting
4.Weight of added water
5.Final dilution weight ratio of water to asphaltic emulsion 30-1.01C(3) Quality Assurance Submittals 30-1.01C(3)(a) General Reserved 30-1.01C(3)(b) Test Strip Submit a summary of the determinations made from test strips. 30-1.01C(3)(c) Quality Cont rol Reporting For each lot, submit a daily report that includes the following items based on the frequencies specified in the table for s ampling locations and testing frequencies for the type of pavement recycling work performed or if not specified, once p er lot:
1.General Information: 1.1. Lot number 1.2. Location description 1.3. Beginning and ending stations 1.4. Lane number and offset from centerline
2.A summary of any weight or load slips for each weighed material indicating truck and trailer numbers, tare weight, gross weight, net weight, and date
3.For asphalt emulsion used on finished recycled pavement surface, if asphaltic emulsion is specified: 3.1. Emulsion type SECTION 30 RECYCLED PAVEMENT 3.2. Emulsion application rate in gal/sq yd 3.3. Emulsion dilution as the we ight ratio of added water to the original asphaltic emulsion
4.Calculated supplementary aggregate application rate in lb/sq yd and percent of dry weight of recycled processed material if supplementary aggregate is specified
5.Calculated cement application rate by lb/sq yd and percent dry weight of recycled processed material if cement is specified
6.QC test results for: 6.1. Gradation 6.2. Moisture content, if appl icable 6.3. In-place wet density 6.4. Relative compaction 6.5. Depth of cut
7.Note on the daily report the postmile or station limits of any unsuitable materials locations and when the Engineer was notified Update each day's submitted report within 24 ho urs of obtaining test results. Consolidate all lots completed in a day into one report with each lot reported separately. 30-1.01D Quality Assurance 30-1.01D(1) General Divide the area to be recycled into lots except the 1st test strip is the 1st lot and must be at least 2,000 sq yd. A quantity placed at the end of a work shift greater than 500 sq yd is considered 1 lot. If a quantity of recycled pavement placed at the end of a work shift is less than 500 sq yd, you may either count this quantity as 1 lot or include the test results for quality control in the previous lot. For any lot including the test strip, stop recycled pavement activities and immediately inform the Engineer if any test result does not comply with the specifications. Stop recycled pave ment activities for noncompliance with the specifications. Before resuming activities:
1.Notify the Engineer of the adjustments you will make
2.Remedy or replace the noncompliant lot until it complies with specifications
3.Construct a 1 ,000 sq yd test strip with proposed adjustments demonstrating ability to comply with the specifications
4.Obtain authorization 30-1.01D(2) Preoperation Meeting Schedule a preoperation meeting at a mutually agreed time at the job site to meet with the Engineer. Discuss the project specifications and methods of performing each item of the work. Items discussed must include the processes for:
1.Determining the mix design
2.Production
3.Compacting
4.Grading
5.Finishing
6.Implementing the authorized QC plan
7.Implementing the contingency plan
8.QC sampling and testing
9.Acceptance criteria Preoperation meeting attendees must sign an attendance sheet provided by the Engineer. The preoperation meeting must be attended by your:
1.Project superintendent
2.Project manager
3.QC manager
4.Workers and your subcontractor's workers, including: 4.1. Foremen 4.2. Ground supervisors SECTION 30 RECYCLED PAVEMENT 4.3. Representative from testing lab Do not start pavement recycling activities, including test strips, until the listed personnel have att ended a preoperation meeting. 30-1.01D(3) Test Strip On the 1st day of pavement recycling activities and using the same equipment and materials that will be used during production, construct at least 1,500 feet in a single lane width to determine the:
1.Equipment, materials, and processes can produce recycled pavement in compliance with the specifications
2.Effect of varying the pulverizing machine's forward speed and drum rotation rate on the consistency of the pulverized material
3.Optimal proportions, as applicable, of supplementary aggregate, stabilizing agents, and water
4.Rolling meth od and sequence complies with the compaction and finishing specifications
5.Application rate of asphaltic emulsion, as applicable Do not proceed with recycled pavement activities until the Engineer informs you the test strip is authorized. For production , adjustments to the equipment, material, and process determined by the test strip must be authorized. If QC or acceptance test results are not available, you may proceed at your own risk. 30-1.01D(4) Quality Control 30-1.01D(4)(a) General Laboratories t esting material used to prepare the mix design must be accredited by the AASHTO Accreditation Program and the Department 's Independent Assurance Program. Personnel performing sampling and testing used to prepare the mix design must be certified under the D epartment 's Independent Assurance Program. 30-1.01D(4)(b) Sampling and Testing Take samples under California Test 125. Quality control laboratories must be accredited and personnel performing sampling and testing must be certified under the Department 's Independent Assurance Program. Measure and record the actual cut depth at both ends of the pulverizing drum at least once every 300 feet along the cut length. Take measurements in the Engineer 's presence. 30-1.01D(5) Department Acceptance Reserved 30-1.02 MATERIALS 30-1.02A General Reserved 30-1.02B Supplementary Aggregate If supplementary aggregate is specified, supplementary aggregate must comply with 3/4 inch maximum gradation specified in section 26 -1.02. Supplementary aggregate must not incl ude cinders. Do not use supplementary aggregate with more than 50 percent by volume of recycled asphalt concrete. Supplementary aggregate must weigh at least 105 lb/cu ft, determined under California Test 212, Compacted Method (by Rodding). 30-1.02C Water Notify the Engineer if a water source other than potable water is used and perform testing for chlorides and sulfates before starting work. If potable water is not used, water must be clean and contain no more than 650 parts per million of chlorides as Cl determined under California Test 422 and no more than 1,300 parts per million of sulfates as SO 4 determined under California Test 417. SECTION 30 RECYCLED PAVEMENT 30-1.02D Cement If cement is specified, cement must be Type II or Type V portland cement as specified in ASTM C150/150M. 30-1.02E Asphaltic Emulsion Asphaltic emulsion must be Grade SS -1h or CSS -1h. For dilution, the weight ratio of water added to asphaltic emulsion must not exceed 1 to 1. 30-1.03 CONSTRUCTION 30-1.03A General Except for pulverized roadbed, bef ore starting daily pavement recycling activities sweep the area constructed the previous day to remove loose material. Do not use a heating device to soften the pavement. 30-1.03B Equipment Do not interrupt traffic while servicing equipment . Grading equipment must be a motor grader with automatic grade controls for profile elevation and cross slope. If specified, supplementary aggregate or cement spreading equipment must uniformly distribute the supplementary aggregate o r cement throughout the area to receive it. The spreader must be equipped with working scales or proportioning and distance measuring devices to control the spread rate. If supplementary aggregate or cement is spread before pulverizing the existing pavemen t, the pulverizing equipment must produce a uniform mixture without segregation. 30-1.03C Surface Preparation Before pavement recycling activities start, prepare the existing roadway surface by:
1.Clearing fo reign matter including vegetation .
2.Removing standing water .
3.Referencing the profile and cross slope .
4.Marking the proposed longitudinal cut lines on the existing pavement as follows: 4.1. Cut lines must coincide with points where the existing cross slope changes, approximately at the centerline and edge of traveled way . 4.2. Cut lines must indicate the sequence of the cuts .
5.Referencing existing lane lines and striping layout . If excess material is to be stored adjacent to the shoulder, clear and dispose of the weeds, grass, and debris from the area. 30-1.03D Pulverizing and Mixing If the established grade will cause noncompliance with the thickness requirements, notify the Engineer. If you encounter unstable subgrade or rocks greater than 4 inches in the roadway section notify the Engineer. The Engineer determines the extent of the problem and the corrective measures to be taken. 30-1.03E Compacting and Grading Remove any solids that are larger than 3 inches in the pulverized roadbed mixture before shaping and compacting . 30-1.03F Finishing The finished r ecycled surface must not vary more than 0.05 foot from the lower edge of a 12 -foot straight edge laid in directions parallel and perpendicular to the centerline. 30-1.04 PAYMENT The payment quantity for supplementary aggregate is determined as specified for aggregate base in section 26. SECTION 30 RECYCLED PAVEMENT The payment quantity for asphaltic emulsion is measured under section 94 . 30-2 FULL DEPTH RECYCLING —NO STABILIZER 30-2.01 GENERAL 30-2.01A Summary Section 30 -2 includes specifications for constructing a uniform recycled pavement base by pulverizing the asphalt concrete pavement and underlying material . 30-2.01B Definitions Lot: 2,000 sq yd of full depth recycling —no stabilizer. 30-2.01C Submittals At least 10 days before starting full depth recycling —no stabilizer activities submit the QC plan. The QC plan must include a pulverizing and paving plan outlining the sequence of work, including the maximum production rate for full depth recycling —no stabilizer activities. Submit the test results for the quality characteristics within the times after sampling shown in the following table: Quality characteristic Maximum reporting time allowance Gradation 24 hours Depth of cut In-place wet density Relative compaction 30-2.01D Quality Assurance 30-2.01D(1) General The specifications for a preoperation meeting under section 30 -1.01D(2) do not apply to full depth recycling —no stabilizer . 30-2.01D(2) Quality Control 30-2.01D(2)(a) General Meet with the Engineer 1 week before starting full depth recycling —no stabilize r activities to review the QC plan. Perform sampling and testing for each test strip and production work at the specified frequency for the quality characteristics shown in the following table: Full Depth Recycling —No Stabilizer Quality Characteristic Sampling Locations and Testing Frequencies Quality characteristic Test method Minimum sampling and testing frequency Sampling location Gradation California Test 202 Test strip and 1 per lot Loose mix after pulverizing and mixing Depth of cut --300 feet Both sides of recycling machine along cut length In-place wet density California Test 231 The same locations as relative compaction tests -- Relative compaction California Test 231 One per test strip and 10 random locations per lot Compacted mix 30-2.01D(2)(b) Test Strip Allow 24 hours for authorization of the test strip. 30-2.01D(3) Department Acceptance The Department accepts full depth recycling —no stabilizer based on: SECTION 30 RECYCLED PAVEMENT
1.Visual inspection including: 1.1. Segregation, tearing, and scarring of the finished surface 1.2. Variance of more than 0.05 foot measured from the lower edge of a 12 -foot straightedge 1.3. Uniform surface texture throughout the work limits 1.4. Repaired areas
2.Compliance with the following table: Full Depth Recycling —No Stabilizer Requirements for Acceptance Quality characteristic Test method Requirement Relative compaction (min, %) California Test 231 95 Thickness (ft) Field measurement Not more than 0.05 ft less than the thickness shown 30-2.02 MATERIALS 30-2.02A General The quality characteristics of full depth recycling —no stabilizer must comply with the requirements shown in the following table: Full Depth Recycling —No Stabilizer Quality Characteristic Requirements Quality characteristic Test method Requirement Gradation (%, passing) Sieve Size: 2" 1-1/2" California Test 202 100 90–100 Depth of cut (ft) --Not more than 0.05 ft less than the thickness shown In-place wet density (lb/cu ft) California Test 231 Report only Relative compaction (min, %) California Test 231 95 30-2.02B Sand Cover Reserved 30-2.02C Supplementary Aggregate If supplementary aggregate is specified, supplementary aggregate must comply with the specifications for Class 2 aggregate base in section 26. 30-2.03 CONSTRUCTION 30-2.03A General Reserved 30-2.03B Equipment Pulverizing equipment must:
1.Be a self -propelled recycl ing machine
2.Pulverize the existing pavement and underlying material to the required size
3.Mix the pulverized pavement, underlying material, and water into a homogeneous and uniform mixture
4.Be equipped with automatic depth controls capable of maintaining the cutting depth to within 0.05 foot of the depth shown
5.Have a minimum 8 -foot-wide cutter tha t can remove the existing pavement to the specified depths Compacting equipment must be a sheepsfoot roller, a vibratory steel -tired roller, and a pneumatic -tired roller. All compacting equipment must be self -propelled and reversible. The frequency of amp litude of vibrating rollers must be adjustable and exceed a static force of 15 tons in vibratory mode. 30-2.03C Spreading Reserved SECTION 30 RECYCLED PAVEMENT 30-2.03D Compacting and Grading Reserved 30-2.03E Finishing The finished surface must be free from segregation, tearing, and scarring, and have a uniform surface texture throughout the work limits. Maintain the full depth recycling —no stabilizer surface free of ruts, bumps, indentations, raveling, and segregation. Repair damaged full depth recycling —no stabilizer with minor HMA. 30-2.04 PAYMENT Not Used 30-3 FULL DEPTH RECYCLING —FOAMED ASPHALT 30-3.01 GENERAL 30-3.01A Summary Section 30 -3 includes specifications for constructing a recycled pavement bas e using FDR —foamed asphalt . Constructing an FDR —foamed asphalt base includes :
1.Pulverizing existing asphalt concrete and existing underlying materi als
2.Mixing with water, foamed asphalt, cement, and if required, supplementary aggregate
3.Grading and compacting the mixture
4.Applying asphaltic emulsion 30-3.01B Definitions Lot: 1,000 sq yd of FDR—foamed asphalt . 30-3.01C Submittals 30-3.01C(1) General With the QC plan, submit the m ix design. 30-3.01C(2) Quality Assurance Submittals 30-3.01C(2)(a) General Reserved 30-3.01C(2)(b) Mix Design Submit FDR —foamed asphalt mix design under California Test 313. With the mix design forms, i nclude actual test results, worksheets, photographs, and graphs. The mix design submittal must be sealed and signed by an engineer who is registered as a civil engineer in the State. 30-3.01C(2)(c) Quality Control Reporting With the daily report specified in section 30 -1.01C(3)(c) , submit the following based on the testing frequencies specified or if not specified, once per lot:
1.General Information: 1.1. Weather: 1.1.1. Ambient air temperature before starting daily FDR —foamed asphalt activities includin g time of temperature reading 1.1.2. Road surface temperature before starting daily FDR —foamed asphalt activities including time of temperature reading
2.Asphalt binder: 2.1. Injection rate from controller 2.2. Temperature in degrees F from thermometer in the asphalt binder feed line for each truck load
3.Water application rate by percent dry weight of FDR —foamed asphalt from the controller
4.Average forward speed of pulverizing equipment
5.FDR—foamed asphalt core thickness in feet and location of corin g SECTION 30 RECYCLED PAVEMENT With the daily report, submit the test results for the quality characteristics within the times after sampling shown in the following table: FDR—Foamed Asphalt Quality Characteristic Test Results Reporting Time Allowances Quality characteristic Maximum reporting time allowance Water sulfates Before work starts Water chlorides Moisture content before HMA paving Asphalt binder expansion ratio 24 hours Asphalt binder half -life Gradation Moisture content In-place wet density Relative compaction Indirect dry tensile strength 5 business days Indirect wet tensile strength Tensile strength ratio Before each day of HMA paving, submit a report of the moisture content at mid depth based on the frequency specified in section 30 -3.01D(2)(c) for the area to be paved that day. 30-3.01D Quality Assurance 30-3.01D(1) General 30-3.01D(1)(a) General Relative compaction must be determined under California Test 231 and the following:
1.Nuclear gauge counts are taken at 3 elevations within the FDR—foamed asphalt layer identified as E1, E2, and E 3 measured from the finished FDR—foamed asphalt surface as follows: 1.1. E1 = 1/3 x ( FDR—foamed asphalt thickness -1 inch). 1.2. E2 = 2/3 x ( FDR—foamed asphalt thickness -1 inch). 1.3. E3 = (FDR—foamed asphalt thickness -1 inch). 1.4. Do not take nuclear gauge counts at elevations less than 2 inches below finished surface.
2.Correction for oversize material does not apply.
3.A sample must contain no more than 5 percent retained on the 1 -inch sieve and 10 percent retained on the 3/4 -inch sieve.
4.Use the laboratory wet test maximum density closest in proximity to the lot to determine relative compaction. If the relative compaction for a lot is less than 98 percent, perf orm California Test 216 and California Test 226 for each noncompliant lot and recalculate the relative compaction.
5.Measure relative compaction at each elevation E 1, E2, and E 3. Do not average the elevation compaction measurements at each location. Before starting FDR —foamed asphalt activities, calibrate the asphalt meter in the presence of the Engineer in compliance with the material plant quality program. The Engineer determines the frequency of testing and calibration. Before placing HMA, test moistur e content at mid depth of the FDR —foamed asphalt layer under California Test 226. Sampling must not introduce water to the material. Test in the Engineer's presence. 30-3.01D(1)(b) Preoperation Meeting In addition to the listed personnel in section 30 -1.01D(2), the preoperation meeting must be attended by your:
1.FDR—foamed asphalt machine operators
2.Grading and compacting equipment operators 30-3.01D(1)(c) Test Strip The Engineer tests each test strip under section 30 -3.01D(3) and California Test 371 . SECTION 30 RECYCLED PAVEMENT 30-3.01D(2) Quality Control 30-3.01D(2)(a) General Reserved 30-3.01D(2)(b) Mix Design Sampling and Testing The FDR —foamed asphalt mix design process must comply with California Test 313. Notify the Engineer at least 2 business days before sampling for a mix design. Obtain representative pavement and underlying base material samples for FDR —foamed asphalt from the test pits. If additional samples of subgrade material are needed, test pits can be excavated outside the edge of pavement to vari able dimensions. Characterize and record test pit features such as layer thicknesses and types, distresses, interlayers, thin or thick areas, digouts, and adhesion to the base. Use the sampled material to determine the mix design according to the proportio ns of the pavement structure shown. Before opening the mix design sampling locations to traffic, backfill test pits by replacing and compacting the remaining excavated materials. Place and compact authorized material or minor HMA complying with section 39 -2.07 to the existing grade and thickness of AC, in the Engineer's presence. When mix design sampling is complete at all locations, remove authorized backfill material at test pit locations and place and compact with minor HMA to existing grade. 30-3.01D(2) (c) Quality Control Sampling and Testing Assign a ground supervisor whose sole purpose is to monitor the FDR —foamed asphalt activities, advise project personnel, and interface with the quality control testing personnel. The ground supervisor must not have any sampling or testing duties. Perform sampling and testing for each test strip and at the specified frequency for the quality characteristics shown in the following table: FDR—Foamed Asphalt Quality Characteristic Sampling Locations and Testing Frequenc ies Quality characteristic Test method Sampling location Minimum testing frequency Moisture content before HMA paving California Test 226 Mid depth One per 5 lots Asphalt binder expansion ratio --Asphalt binder spray bar One before start of FDR—foamed asphalt work each day and 2 per day Asphalt binder half -life Gradation California Test 202 Loose mix after pulverizing and mixing Test strip and 1 per lot Moisture content California Test 226 --Test strip and 2 per daya In-place wet density California Test 216 --Test strip and 2 per daya Relative compaction California Test 231 Compacted mix Test strip and 1 per lot Indirect dry tensile strength California Test 371 Loose mix after pulverizing and mixing Test strip Indirect wet tensile strength California Test 371 Tensile strength ratio California Test 371 aIf lot fails minimum test frequency is one per lot. Take a 1 -quart asphalt binder sample and record the temperature from the truck for each load delivered to the job site. Sample asphalt binder in the Engineer's presence and provide the sample to the Engineer. Take 1 thickness core for every lot. Record the location and station or postmile for each thickness core. SECTION 30 RECYCLED PAVEMENT 30-3.01D(3) Department Accep tance The Department accepts FDR —foamed asphalt based on:
1.Visual inspection for: 1.1. Segregation, raveling, and loose material 1.2. Variance of more than 0.05 foot measured from the lower edge of a 12 -foot straightedge 1.3. Uniform surface texture thro ughout the work limits 1.4. Repaired areas
2.Compliance with the quality characteristics shown in the following table: FDR—Foamed Asphalt Requirements for Acceptance Quality characteristic Test method Requirements Relative compaction (%, min) California Test 231 98% at each elevation E 1, E2, and E 3 Thickness (ft)a Core measurements ±0.05 ft of the specified thickness aTake 4 -or 6-inch cores from random locations the Engineer selects. The Engineer may require 3 locations per lot, coring more than three locations per lot is change order work. At time of coring, submit cores to the Engineer for measurement. 30-3.02 MATERIALS 30-3.02A General The quality characteristics of the FDR—foamed asphalt must comply with the requirements shown in the following table: FDR—Foamed Asphalt Quality Characteristic Requirements Quality characteristic Test method Requirement Moisture content before HMA paving California Test 226 < 50% of OMC Asphalt binder expansion ratio (min, %) 10 Asphalt binder half -life (seconds, min) Note a 12 Gradation (%, passing) Sieve size: 3" 2" 1-1/2" California Test 202 100 95–100 85–100 Moisture content Maximum Minimum California Test 226 OMC OMC -2% In-place wet density (lb/cu ft) California Test 216 Report only Relative compaction (min, %) California Test 231 98 Indirect dry tensile strength (psi)b California Test 371 90% of mix design value Indirect wet tensile strength (psi)b California Test 371 90% of mix design value Tensile strength ratio (%) California Test 371 90% of mix design value aTest at the foaming temperature and percentage of foaming water by dry weight of FDR—foamed asphalt material designated in the mix design. To test asphalt binder expansion ratio and h alf-life, use a pail of known volume and a dipstick calibrated for the pail. From the inspection nozzle on the asphalt binder spray bar, inject foamed asphalt into the pail without exceeding the pail's capacity. With the dipstick, immediately measure and r ecord the level of foamed asphalt in the pail. Record the half-life in seconds from the time the injection of foamed asphalt in the pail is turned off to half the dip stick reading after peak. Calculate the expansion ratio as the volume of the foamed aspha lt upon injection divided by the volume of the unfoamed asphalt binder. bFrom material passing the 1 -inch sieve, compact 6 specimens under California Test 304, Part 2. Cure the specimens at 100 °F for 72 hours and allow the specimens to cool to room temper ature. Test 3 specimens for dry tensile strength under California Test 371. Test 3 specimens for wet tensile strength under California Test 371 after moisture conditioning. 30-3.02B Asphalt Binder Asphalt binder must be PG 64 -10. SECTION 30 RECYCLED PAVEMENT Do not heat asphalt binder above 375 degree s F. 30-3.02C Core Backfill Material Material to fill cored holes for thickness measurements must be packaged rapid -hardening cementitious material under ASTM C928, Type R2 or R3. 30-3.03 CONSTRUCTION 30-3.03A General Do n ot start FDR —foamed asphalt activities if the ambient air temperature is below 50 degrees F or the road surface is below 50 degrees F. If the ambient air temperature falls below 50 degrees F during FDR—foamed asphalt activities, you may only compact and fi nish FDR —foamed asphalt . 30-3.03B Equipment The FDR —foamed asphalt machine must have independent and interlocked systems for water and foamed asphalt, and each must include:
1.Digital electronic controller system
2.Pumping system
3.Spray bar system Based on the mix design of the material being recycled and the equipment's forward speed:
1.Controller, pumping, and spray bar systems must regulate the foamed asphalt and the moisture content of the full pulverized material
2.Rate by weight of foaming wat er must be controlled with the same controller Spray bars must be fitted with self -cleaning nozzles or nozzles that indicate flow. Space the nozzles evenly at a rate of 1 nozzle for every 6 to 8 inches of mixing chamber width. Apply the asphalt binder atomized under pressure through individual and separate small orifices. Fit an inspection nozzle at 1 end of the asphalt binder spray bar. The inspection nozzle must produce a representative sample of foamed asphalt. Asphalt binder storage equipment must:
1.Be attached to the FDR—foamed asphalt machine
2.Not leak
3.Have a sampling valve
4.Have a heating system to maintain the temperature of asphalt binder above 340 degrees F including when the asphalt binder is injected
5.Have a thermometer in t he asphalt binder feed line before introduction of water Use a mass flow, Coriolis effect type asphalt meter with a visible readout display, and printing capabilities. The distance from the foamed asphalt spray nozzle to the top of the cutter tooth holder must be at least equal to the cut depth. Storage equipment for compaction water must be attached to the FDR —foamed asphalt machine and not leak. The FDR —foamed asphalt machine must spread the mixed material or a screed mounted on the machine may be used. Compacting equipment must consist of 1 vibratory sheepsfoot roller with a blade for each FDR —foamed asphalt machine, a vibratory steel drum roller, and a pneumatic -tired roller. All compacting equipment must be self -propelled and reversible. The frequency and amplitude of vibrating rollers must be adjustable and exceed a force of 15 tons in vibratory mode. 30-3.03C Spreading Materials Reserved SECTION 30 RECYCLED PAVEMENT 30-3.03D Pulverizing and Mixing Do not leave a wedge where the pulverizing drum cuts into the existing material. The 1st cut width must use the full width of the pulverizing drum. Subsequent cuts must overlap by at least 4 inches. Do not leave a gap of unpulverized material between cuts. With each cut, adjust the quantity of water and foamed asphalt proportionally to the actual cut width. If a cut deviates more than 4 inches outside the cut line, immediately adjust. If a cut deviates more than 4 inches inside the cut line, immediatel y back up and pulverize the deviation along the correct cut line without adding water or foamed asphalt. Mark the existing pavement where the center of the pulverizing drum stops. Start the following cut on this alignment at least 2 feet behind the mark. The injection rate of asphalt binder must be the percent by dry weight of pulverized material designated in the mix design but not less than 2.5 percent. Notify the Engineer if adjustments to the asphalt binder injection rate are necessary. The injection ra te of mixing water must be sufficient to produce the FDR —foamed asphalt material moisture content shown in table titled " FDR—Foamed Asphalt Quality Characteristic Requirements " at time of compaction. Do not apply water to an uncompacted surface. Do not all ow more than 3 hours between mixing the pulverized material with foamed asphalt and cement and completion of compaction with vibratory steel drum rollers. 30-3.03E Compacting and Grading Immediately after pulverizing and mixing, compact FDR —foamed asphalt with a sheepsfoot roller. Each sheepsfoot roller must stay within 100 feet of its FDR —foamed asphalt train. Do not add water or use a motor grader to spread material unt il initial compaction with sheepsfoot rollers is complete. During grading and final compaction with vibratory steel drum rollers, add water to maintain the moisture content as shown in the table titled, " FDR—Foamed Asphalt Quality Characteristic Requiremen ts." 30-3.03F Finishing Immediately after compaction, apply water and roll with pneumatic -tired rollers or steel drum roller with no vibration. The finished surface must be free of ruts, bumps, indentations, segregation, raveling, and any loose material. Keep the compacted surface damp by lightly watering until asphaltic emulsion is applied. Apply a coat of diluted asphaltic emulsion to t he finished surface when it is damp but free of standing water. The application rate of asphaltic emulsion must be from 0.13 to 0.25 gal/sq yd. Do not water after applying asphaltic emulsion. Place temporary traffic control. Do not open to traffic without the Engineer's authorization. Maintain the FDR —foamed asphalt surface free of ruts, bumps, indentations, raveling, and segregation. Repair damaged FDR —foamed asphalt material with minor HMA. Take cores to determine the finished FDR —foamed asphalt thickness before placing HMA. If a core indicates FDR —foamed asphalt thickness is less than the specified thickness by more than 0.05 foot, core in the vicinity of the noncompliant core to determine the extent of the deficient thickness. Remove the FDR —foamed aspha lt material deficient in thickness by cold planing to a depth of 0.2 foot below the finished FDR —foamed asphalt grade. Replace the planed FDR —foamed asphalt with the HMA specified for the project and compact under the method compaction specifications in se ction 39 -2.01C. Immediately before placing HMA, apply asphaltic emulsion at a rate from 0.03 to 0.05 percent residual binder content. Do not place HMA until authorized. 30-3.04 PAYMENT The payment quantity for asphalt binder is measured as specified for a sphalt in section 92 -1.04. SECTION 30 RECYCLED PAVEMENT The Department does not adjust the unit price for an increase or decrease in cement or asphalt binder quantities. 30-4 FULL DEPTH REC YCLING —CEMENT 30-4.01 GENERAL 30-4.01A Summary Constructing an FDR —cement includes :
1.Pulverizing existing asphalt concrete pavement with underlying materials
2.Rough grading, shaping, and rolling the pulverized material to the lines, grades, and cross sections shown
3.Removing a nd disposing of excess pulverized material or adding supplementa ry aggregate as required
4.Spreading cement on the pulverized material and mixing the material with water
5.Compacting the mixture
6.Fine grading the mixture to the lines, grades, and cross sections shown
7.Applying asphaltic emulsion and sand cover
8.Microcracking the completed surface 30-4.01B Definitions Lot: 1,000 sq yd of FDR—cement . 30-4.01C Submittals 30-4.01C(1) General With the QC plan, submit the mix design. Submit quality control test results along with the daily reports. Submit QC test results within 3 business days of completing each QC test. For submittal of test results, go to the Data Interchange for Materials Engineering website. 30-4.01C(2) Quality Assurance Submittals 30-4.01C(2)(a) General Reserved 30-4.01C(2)(b) Mix Design Submit each FDR—cement m ix design at least 15 days before starting FDR —cement operations. Each mix design submittal must be sealed and signed by an engineer who is registered as a civi l engineer in the State. You may submit multiple mix designs to optimize the cement content and adjust for varying underlying materials. Each mix design submittal must include:
1.Area represented by the mix design by beginning and ending stations
2.Grada tion of the mixture before addition of cement
3.Cement content in percent by weight of the dry mixture and in lb/sq yd surface application rate
4.Supplementary aggregate in percent by weight of the dry mixture, if supplementary aggregate is specified
5.Test results and any worksheets, photographs, and graphs
6.Unconfined compressive strength test results
7.Moisture -density curve including optimum moisture content of the material at the specified cement content
8.Certificate of compliance for cement 30-4.01C(2)(c) Quality Control Reporting With the daily report, submit the following based on the testing frequencies specified: SECTION 30 RECYCLED PAVEMENT
1.General Information: 1.1. Weather: 1.1.1. Ambient air temperature before starting daily FDR—cement activities, including ti me of temperature reading 1.1.2. Road surface temperature before starting daily FDR—cement activities, including time of temperature reading
2.Average forward speed of pulverizing equipment
3.FDR—cement quality control test results for unconfined compres sive strength
4.Depth of pulverization With the daily report , submit the test results for the quality characteristics within the times shown in the following table: FDR—Cement Quality Characteristic Test Result Reporting Time Allowances Quality characteristic Maximum reporting time allowance Water sulfates Before work starts Water chlorides Gradation 24 hours after sampling Moisture content Laboratory maximum wet density Relative compaction Unconfined compressive strength 24 hours after testing specimens 30-4.01D Quality Assurance 30-4.01D(1) General Relative compaction must be determined under California Test 231 and the following:
1.For a recycled layer 0.5 -foot thick and less, perform 1 relative density test at mid layer. For thickness greater than 0.5 -foot, test at 0.5 -foot intervals from 2 inches above the bottom of the FDR —cement layer.
2.A sample must contain no more than 5 percent retained on the 2 -inch sieve and 15 percent retained on the 1 -1/2-inch sieve.
3.Correction for oversize material does not apply.
4.Use the lab oratory wet test maximum density closest in proximity to the lot to determine relative compaction. If the relative compaction for a lot is less than 95 percent in accordance with ASTM D1557 requirements, perform California Test 216 and California Test 226 for each noncompliant lot and recalculate the relative compaction. The Engineer tests each test strip under section 30-4.01D(4) . 30-4.01D(2) Mix Design Develop a mix design under California Test 314 for each materials sampling location. The mix design must produce FDR—cement with an unconfined compressive strength from 300 to 450 psi. Notify the Engineer at least 2 business days before sampling. Use materials from the specified FDR —cement mixing depth. If any portion of existing asphalt concrete pavement is to be removed before pulverizing, remove that portion of asphalt concrete pavement from the samples used in the mix design. If additional samples of subgrade material are needed, sampling locations can be excavated outside the edge of pavement to variab le dimensions. Characterize and record sampling location features such as layer thicknesses and types, distresses, interlayers, thin or thick areas, digouts, and adhesion to the base. Use the sampled material to determine the mix design represented by the sampling location, according to the proportions of the pavement structure shown. Before opening the mix design sampling locations to traffic, backfill sampling locations by replacing and compacting with an authorized material or minor HMA that complies wit h section 39 -2.07. Backfill and compact to the existing grade and thickness of asphalt concrete pavement, in the Engineer's presence. SECTION 30 RECYCLED PAVEMENT 30-4.01D(3) Quality Control 30-4.01D(3)(a) General Reserved 30-4.01D(3)(b) Sampling and Testing Assign a ground supervisor whose sole purpose is to monitor the FDR —cement activities, advise project personnel, and interface with the quality control testing personnel. The ground supervisor must not have any sampling or testing duties. Test the quality characteristics of FDR —cement shown in the following table: FDR—Cement Quality Characteristic Sampling Locations and Testing Frequencies Quality characteristic Test method Minimum sampling and testing frequency Sampling location Aggregate gradation California Test 202 Test strip and 1 per 2 lots Loose mix after pulverizing and mixing Moisture content California Test 226 Test strip and 2 per day of productiona Loose mix after pulverizing and mixingbUnconfined compressive strengthd ASTM D1633 Test strip and 1 per 2 lots Laboratory maximum wet density California Test 216 Test strip and 2 per day of production Same location as California Test 231 Relative compactionc California Test 231 Test strip and 1 per lot Compacted mix aIf test fails, minimum test frequency is 1 per lot. bSample immediately after mixing is complete. cVerify the moisture content reading made under California Test 231 with California Test 226. dCompact FDR —cement test specimens under ASTM D1557, Method B. Measure and record the actual cut depth at both ends of the pulverizing drum at least once every 300 feet along the cut length. Take measurements in the Engineer's presence. 30-4.01D(4) Department Acceptance The Department accepts FDR —cement before placing HMA surface wearing c ourse, based on:
1.Visual inspection for the following: 1.1. No segregation, raveling, or loose material 1.2. Variance must not be more than 0.05 foot measured from the lower edge of a 12 -foot straightedge 1.3. Uniform surface texture throughout the work limits
2.Compliance with the quality characteristics shown in the following table: FDR—Cement Requirements for Acceptance Quality characteristic Test method Value Cement application rate (lb/sq yd) Calibrated tray or equal Mix design rate ± 5% Relative compaction (min, %, wet density) California Test 231 95
3.FDR—cement thickness for each lot. The thickness must be within 0.05 foot of the thickness shown. Verify the thickness at a location determined by the Engineer by taking 4 -or 6-inch cores or by other authorized methods. If coring is performed, backfill cores with similar strength material. 30-4.02 MATERIALS 30-4.02A General The quality characteristics for the FDR —cement must comply with the requ irements shown in the following table: SECTION 30 RECYCLED PAVEMENT FDR—Cement Quality Characteristic Requirements Quality characteristic Test method Requirement Aggregate gradation (%, passing)a Sieve size: 3 “ 2 “ 1-1/2 “ No. 4 California Test 202 100 95–100 85–100 >55 Moisture content (%) California Test 226 Mix design ± 2 percent Unconfined compressive strength (psi) ASTM D1633 b 300–450 Laboratory maximum wet density (lb/cu ft) California Test 216 Use for relative compaction calculation Relative compaction (min, %, wet density)c California Test 231 95 aPerform aggregate gradation on samples collected from full recycled depth. bPrepare, c ompact , and cure FDR—cement test specimens under California Test 314, Sections H.4.1, H.4.2, and H.4.3. cVerify the moisture content reading made under California Test 231 with California Test 226. 30-4.02B Cement Reserved 30-4.02C Water Reserved 30-4.02D Supplementary Aggregate If supplementary aggregate is specified, supplementary aggregate must comply with the specifications for Class 2 aggregate base in section 26. 30-4.02E Asphaltic Emulsion Asphaltic emulsion must be Grade SS -1h or CSS -1h. Notify the Engineer if you dilute the asphaltic emulsion with water. The ratio by weight of added water to asphaltic emulsion must not exceed 1 to 1. Measure added water weight. 30-4.02F Sand Cover Sand used for sand cover must comply with the material specifications for fine aggregate un der section 90-1.02C(3). Sand must not contain more than 2 percent moisture by dry weight of sand. 30-4.02G Test Pit Backfill Material Backfill for test pits must be FDR —cement treated material. 30-4.03 CONSTRUCTION 30-4.03A General Do not start FDR —cement activities if the ambient air temperature is below 40 degrees F or the road surface is below 40 degrees F. If the ambient air temperature falls below 40 degrees F during FDR — cement activities, you may not spread or mix cement, you may only compact and finish already mixed FDR-cement material . Backfill test pits and compact to 95 percent under California Test 231. After compaction, the repair area must not vary more than 0.05 foot from the adjacent FDR —cement surface . 30-4.03B Equipment The FDR —cement mixing machine must have independent and interlocked systems for water and must include the following: SECTION 30 RECYCLED PAVEMENT
1.Digital electronic controller system
2.Pumping system
3.Spray bar system The cement distributor must have a vacuum or dust suppressant system to minimize airborne cement during spreading of the cement on the grade. Storage equipment for water must not leak and must be attached to the FDR —cement mixing machine with a tow bar and hose. The hose must be attached to the bar and m ust not touch the ground at any time. Grading and compacting equipment must be self -propelled and reversible. The frequency and amplitude of vibrating rollers must be adjustable and exceed a force of 15 tons in vibratory mode . 30-4.03C Pulverizing Unless otherwise authorized, do not pulverize more material than can be mixed with cement and compacted in one day. Do not leave a wedge where the pulverizing drum cuts into the existing material. The 1st cut width must use the full width of the pulverizin g drum. Subsequent cuts must overlap at least 4 inches. Do not leave a gap of unpulverized material between cuts. If an overlap is less than 4 inches, immediately back up and pulverize the deviation along the correct cut line. Mark the existing pavement wh ere the center of the pulverizing drum stops. Start the following cut on this alignment at least 2 feet behind the mark. 30-4.03D Spreading Materials Spread cement uniformly over the full roadway surface width. Do not spread cement more than 30 minutes be fore mixing. Do not apply dry cement in windy conditions that will result in dust outside the FDR—cement area. The spread rate must be the mix design rate or the ordered rate in lb/sq yd ± 5 percent. Do not spread cement and supplementary aggregate before pulverizing. 30-4.03E Mixing The overlap requirements in section 30-4.03C apply to mixing. With each cut, adjust the quantity of water proportionally to the actual cut width. If an overlap is less than 4 inches, immediately back up and pulverize the devia tion along the correct line without adding water or cement. Water must be injected through the mixing machine. The injection rate of mixing water must be sufficient to produce the FDR —cement material mixing moisture content described in the mix design. Mark where the center of the pulverizing drum stops. Start the following cut on this alignment at least 2 feet behind the mark. 30-4.03F Compacting and Grading Compact FDR —cement to the minimum relative compaction. Do not allow more than 2 hours between final mixing of the pulverized material with cement and completion of compaction. Check thickness of compacted FDR material in test pit with phenolphthalein prior to final compaction and grading. During grading and final compaction with vibratory steel drum ro llers, add water to maintain the mixing moisture content as described in the mix design. After final compaction, do not place cement treated soil to fill low areas in the grade. 30-4.03G Finishing Immediately after final compaction, apply water and roll w ith pneumatic -tired rollers or steel drum roller with no vibration. The finished surface must be free of ruts, bumps, indentations, segregation, raveling, and any loose material. Keep the compacted surface damp by lightly watering until asphaltic emulsion is applied. Apply a diluted asphaltic emulsion to the finished surface when it is damp but free of standing water at the end of the day. SECTION 30 RECYCLED PAVEMENT The application rate of asphaltic emulsion must be from 0.13 to 0.25 gal/sq . yd. Do not water after applying asphaltic emulsion. Spread sand cover after asphaltic emulsion is applied under section 37 -4.03C. Remove excess sand from the surface by sweeping before opening to traffic. During the period from 48 to 56 hours after final compaction, microcrack the surface by apply ing 2 to 3 single passes using a 12 -ton vibratory steel drum roller at maximum amplitude travelling from 2 to 3 mph. Do not microcrack an FDR—cement layer that is less than 8 inches thick. Maintain the FDR —cement surface free of ruts, bumps, indentations, raveling, and segregation. Repair damaged FDR —cement material with minor HMA. Determine the finished FDR —cement thickness before placing HMA. If FDR —cement thickness is less than the specified thickness by more than 0.05 foot, excavate a test pit at least 1 by 1 -foot in the vicinity of the noncompliant test pit to determine the extent of the deficient thickness. Remove the FDR —cement material deficient in thickness by cold planing to a depth of 0.2 foot below the finished FDR —cement grade. Replace the plane d FDR —cement with the HMA specified for the project and compact under section 39 -2.01C. For each lot of FDR —cement, the HMA layer must be placed within 7 days from final compaction of the FDR—cement unless otherwise authorized. Immediately before placing H MA, apply asphaltic emulsion at a rate from 0.03 to 0.05 percent residual binder content. Do not place HMA until authorized. 30-4.04 PAYMENT Not Used 30-5 PARTIAL DEPTH RECYCLING 30-5.01 GENERAL 30-5.01A Summary Section 30 -5 includes specifications for constructing the pavement using PDR. PDR includes :
1.Cold-planing the existing asphalt concrete pavement to the depth shown
2.Mixing the cold -planed material with recycling agent, cement , and water
3.Spreading and compacting the mixture
4.Applying asphaltic emulsion and sand cover 30-5.01B Definitions action limit: Test results at which corrective actions must be made while production continues. break-over point: Maximum density of the PDR section achieved when nuclear density tests do not show an increase in density after additional compaction passes. cold in-place recycling : General term for in -place recycling of asphalt pavement without application of heat. in-place recycled pavement material: Combination of processed in -place asphalt pavement material with recycling agent. lot: 2,640 linear feet or fraction thereof of PDR pavement constructed in the same day. partial depth recycling: Type of cold in-place recycling where only the HMA layers are recycled and no underlying laye r material is incorporated. recycling agent: Cationic emulsified asphalt or foamed asphalt used in the recycling process. sub-lot: 528 linear feet or fraction thereof of PDR pavement constructed in the same day. SECTION 30 RECYCLED PAVEMENT suspension limit: Test results at which prod uction must be suspended while corrections are made. weight of dry in -place recycled pavement material: Weight is either based on actual weight of in -place recycled pavement as measured by PDR equipment, or on calculated weight of in -place recycled pavemen t using unit weight provided in approved PDR mix design. The type of equipment used to perform PDR is the deciding factor for how weight of in -place recycled pavement is determined. If calibrated belt scales are used on PDR equipment for proportioning of r ecycling agent, then measured weight must be used. If forward distance and volumetrics are used on PDR equipment for proportioning of recycling agent, then calculated weight must be used. 30-5.01C Submittals 30-5.01C(1) General Submit all the test result s, including report only requirements, to the Data Interchange for Materials Engineering website. At least 20 days before starting PDR work, submit the following:
1.Quality control plan
2.Mix design
3.Contingency plan 30-5.01C(2) Quality Control Plan The Engineer reviews the QC plan within 5 business days from the submittal. Do not start PDR production, without the Engineer 's authorization of the QC plan. If QC procedures, personnel, tester qualifications, or lab accreditation status chang es, submit a QC plan supplement at least 3 business days before implementing proposed changes. If a change is needed in your QC plan, do not implement the change without the Engineer 's authorization. 30-5.01C(3) Mix Design For each PDR mix design, submit:
1.Mix design documentation on the Contractor PDR u sing recycling agent Mix Design form per CTM 315, including all raw test data and calculations
2.SDS for: 2.1. Recycling agent 2.2. Cement 2.3. Other additives
3.Manufacturer 's certificate of compliance for: 3.1. Recycling agent 3.2. Cement 3.3. Other additives 30-5.01C(4) Contingency Plan The c ontingency plan must include actions you will take to ensure the roadway will be open to traffic at the end of each work shift. The contingency plan must includ e provisions for constructing a temporary structural section and reopening the roadway to traffic. 30-5.01C(5) Quality Control Reporting For each lot, submit a daily report that includes the following items:
1.General Information: 1.1. Lot and sub -lot nu mber 1.2. Location description 1.3. Beginning and ending station 1.4. Lane number and offset from centerline 1.5. Temperature: 1.5.1. Ambient air temperature before beginning PDR activities including time of temperature reading SECTION 30 RECYCLED PAVEMENT 1.5.2. Road surface temperatures before beginning PDR activities including time of temperature reading
2.For emulsified asphalt or foamed asphalt recycling agent: 2.1. Weight in tons 2.2. Percentage by weight of dry in -place recycled pavement material
3.For cement: 3.1. Application rate by lb/sq yd, if you spread cement directly to the existing pavement, take surface area measurements to calculate applied spread rate and submit with the quantity of cement used, area covered, and certified weight tickets 3.2. Total weight in tons 3.3. Percentage by weight of dry in -place recycled pavement material
4.Water application rate from recycler controllers: 4.1. Used for foaming asphalt by weight of asphalt for PDR -FA 4.2. Added during mixing for compaction by theoretical percent dry weight of PDR
5.For PDR processing: 5.1. Length, width, depth of cut at each end of the milling drum at least every 300 feet along the cut length 5.2. Average forward speed 5.3. Calculated weight in tons of material processed 5.4. Break -over point used fo r relative compaction calculation
6.Straightedge measurement locations and the following: 6.1. Variance measured from the lower edge of a 12 -foot straightedge placed parallel with the centerline 6.2. Variance measured from the lower edge of a 12 -foot str aightedge placed transverse
7.PDR quality control test results for: 7.1. Wet field gradation for material passing the 1 -inch, 3/4 -inch, and no. 4 sieves under AASHTO T 7.2. Relative compaction under California Test 231 for lifts greater than 4 inches a nd relative compaction under California Test 375 for lifts less than or equal to 4 inches 7.3. PDR -EA and PDR -FA tests for I ndirect Tensile Strength under California Test 372
8.For asphaltic emulsion used on finished PDR surface: 8.1. Emulsion type 8.2. Emulsion application rate in gal/sq yd 8.3. Emulsion dilution as the weight ratio of added water to asphaltic emulsion
9.Rate of sand cover application
10.Note on the daily report postmile or station limits of any: 10.1. Changes to recycling agent a pplication rate, including application rate change and reasons for change 10.2. Changes to water application rate, including application rate change and reasons for change for: 10.2.1. Water for foaming for PDR -FA only 10.2.2. Water added for compaction 10.3. Unsuitable material locations and when the Engineer was notified Update each day's submitted report within 24 hours of obtaining test results. Consolidate all of the lots completed in a day into one report with each lot reported separately. During PDR activities, submit the following items daily:
1.Square yards of recycled pavement materia l
2.Tons of recycling agent utilized
3.Tons of recycling agent to be carried over to next production day
4.Tons of cement utilized and spread rate
5.Tons of ceme nt to be carried over to next production day 30-5.01C(6) Certificates Submit certificates of compliance for the cement, recycling agent , and asphaltic emulsion with each delivery. Include the manufacturer 's test results for recycling agent and asphaltic emulsion with your certificate of compliance. The test results must be from material tested within 30 days prior to delivery. SECTION 30 RECYCLED PAVEMENT Submit a certified copy of each delivery's weight for recycling agent, cement, asphaltic emulsion, and sand. 30-5.01C(7) Recyclin g Agent Submit 2 samples of recycling agent in 1 -quart metal cans to the Engineer. Within 10 days after taking recycling agent quality control samples, submit the test results for recycling agent quality characteristics. 30-5.01C(8) Asphaltic Emulsion Submit 2 samples of cationic emulsified asphalt in 1 -quart plastic cans to the Engineer. Within 10 days after taking asphaltic emulsion quality control samples, submit the test results for asphaltic emulsion. Each time you dilute the asphaltic emulsion, submit data according to section 30 -1.01C(2). 30-5.01C(9) Partial Depth Recycling Submit quality control test results for the quality characteristics within the reporting times allowance after sampling shown in the following tables: PDR Quality Control Test Result Reporting Quality characteristic Test method Maximum reporting time allowance Water sulfates (max, ppm) California Test 417 Before work starts Water chlorides (max, ppm) California Test 422 Asphalt expansion for PDR -FA (min, volume) Visual inspection 24 hours Asphalt half -life for PDR -FA (min, seconds) Visual inspection Maximum wet gradation (% passing) Sieve size: 1-1/4" AASHTO T 27 24 hours Wet field gradation (% passing) Sieve size : 1-1/4" 1" 3/4" No. 4 AASHTO T 27 24 hours Dry gradation (% passing) Sieve size : 1-1/4" 1" 3/4" No. 4 No. 30 No. 200 AASHTO T 27 10 days In-place wet density (g/cc) California Test 375, Part 4 or California Test 231 24 hours Relative compaction (min, %) California Test 375 or California Test 231 24 hours Thickness (inch) : Each core Average thickness of cores Core measurements 24 hours Indirect dry tensile strength (psi) California Test 372 10 days Indirect wet tensile strength (min, psi) California Test 372 10 days SECTION 30 RECYCLED PAVEMENT 30-5.01C(10) Partial Depth Recycling Surface Smoothness Submit the PPF files for the initial PDR surface and the corrected PDR surface as shown in section 36 - 3.01C. Use the required naming convention, except for where : X = PDRPAVE for the initial PDR surface, and PDRCORR for the corrected PDR surface. Include both PDR profiles in the ProVAL project file and payment adjustment spreadsheet required for the smoothness payment adjustment request for the hot mix asphalt pavement placed over the PDR surface. 30-5.01D Quality Assurance 30-5.01D(1) General Reserved 30-5.01D(2) Quality Control 30-5.01D(2)(a) General If you adjust the application rate of PDR recycling agent, fog seal, cement, and water, record the adjustments and documen t the reasons for the adjustments in your daily report submittal to the Engineer. 30-5.01D(2)(b) Quality Control Plan The QC plan must describe the organization, responsible parties, and procedures you will use to perform the following:
1.Control the production process
2.Determine whether a change to the production process is needed
3.Obtain samples, including determin ing sampling locations
4.Control quality, including sampling, testing, and reporting
5.Determine action limits when corrective actions are needed
6.Implement corrective actions
7.Ensure PDR cold -planing, mixing, spreading, compacting, and finishing act ivities are coordinated The QC plan must include the action and suspension limits , and the details of the corrective action to be taken if any process is outside of those limits. The suspension limits must not exceed the specified acceptance criteria. The QC plan must address the elements affecting PDR quality including:
1.In-place recycled pavement material
2.Recycling agent
3.Cement
4.Production
5.Paving
6.Compaction
7.Smoothness The QC plan must contain copies of the forms that will be used to p rovide the required inspection records and the sampling and testing results. The QC plan must include the name of your authorized laboratory. 30-5.01D(2)(c) PDR Preconstruction Meeting At least 10 days before starting PDR activities, meet with the Enginee r for a PDR preconstruction meeting at a mutually agreed time and place. Discuss the QC plan and the methods of performing PDR production and placement. This meeting may also include the JIT training . The following personnel must attend the preconstruction meeting:
1.Project manager
2.Project superintendent
3.QC manager
4.Workers and your subc ontractor's workers, including: 4.1. Foremen SECTION 30 RECYCLED PAVEMENT 4.2. Ground supervisors 4.3. Representative from quality control testing lab 30-5.01D(2)(d) Just-in-Time Training At least 5 days and at most 14 days before starting PDR activities, complete a JIT training at a mutually agreed time and place with the Engineer. The JIT training must consist of a formal joint training class on cold recycled asphalt materials, r equired special equipment, placement and compaction methods, and quality control. The instructor will also discuss the QC plan , PDR testing , and evaluation procedures during the training. Construction operations for cold recycling must begin after Contract or's and the Engineer's personnel have completed the JIT training . The JIT training must be held during regular working hours. Provide the JIT training instructor. The instructor must be experienced in the construction methods, materials, and test methods associated with the construction of cold recycled asphalt projects. The JIT training must include the following topics:
1.Recycling application and process
2.Specification requirements for QC testing and the Department acceptance
3.PDR mix design
4.PDR construction
5.Maintenance and protection of the PDR before the final surface of the HMA placement
6.Questions and answers A copy of the training syllabus, handouts, and presentation material must be submitted to the Engineer at least 7 days before the training day for review and acceptance. The JIT training does not relieve you of your responsibility under the contract for the successful completion of the work in conformance with the requirements of the plans and specifications . The following personnel must be represented at the JIT training :
1.Project manager
2.Project superintendent
3.PDR QC manager
4.Field construction leadership, including: 4.1. PDR paving foreman 4.2. PDR production foreman 4.3. Representative from PDR quality control testing l ab 4.4. Representative from PDR quality assurance testing lab
5.The Engineer and personnel 30-5.01D(2)(e) Test Strip 30-5.01D(2)(e) (i) General On the first day of PDR activities and within the pavement area to receive PDR, construct a test strip. The test strip must be a single lane width and at least 1,056 feet in length. The test strip must show:
1.How the proposed equipment, materials, and processes can produce and place the PDR mixture
2.How varying the forward speed and drum rotation rate of the cold -planing machine affect the consistency of the mixture
3.Application rates for asphalt, cement, and water
4.Rolling pattern needed to reach break -over po int
5.Application rates of asphaltic emulsion and sand cover Document the established rolling pattern and submit to the Engineer . The Engineer will evaluate the test strip for authorization based on:
1.Visual inspection for the following: 1.1. Segregati on, raveling, rutting, humps, depressions, roller marks, and loose materia l SECTION 30 RECYCLED PAVEMENT 1.2. Uniform surface texture throughout the work limits
2.Wet gradation
3.Smoothness
4.Relative compaction For smoothness, only the straightedge requirements apply for test strip authorization. Retest the test strip smoothness under section 30-5.01D(2)(e)(i)(F). Rework and recompact or remove and replace test strip if it does not comply with the specifications. Do not proceed with PDR activities until the Engineer authorize s the test strip. 30-5.01D(2)(e)(i i) Quality Control Testing 30-5.01D(2)(e)(i i)(A) General Take samples under California Test 125. For any lot including the test strip, stop PDR construction and immediately notify the Engineer whenever any test result does not comply with the quality characteristic requirements or your quality control plan suspension limits. If PDR activities are stopped for noncompliance, before resuming construction:
1.Notify the Engineer of the adjustments you will make
2.Reprocess, remedy, or replace the noncompliant lot 30-5.01D(2)(e)(ii)(B) Recycling Agent During PDR activities, take four 1 -quart samples of recycling agent from each load delivered to the job site in t he presence of the Engineer. Use 2 samples for QC testing and submit 2 samples to the Engineer. For foamed asphalt, perform sampling and testing of asphalt binder for compliance with the quality characteristics requirements in section 92 table "PG Asphalt Binder " for the performance grade of asphalt used. For emulsified asphalt, the authorized laboratory must perform sampling and testing every fifth tanker load according to section 94 -1.02E. Store recycling agent samples in clean, dry, and sealed 1 -quart co ntainers at a temperature from 40 to 100 degrees F. 30-5.01D(2)(e)(i i)(C) Asphaltic Emulsion Circulate asphaltic emulsion in the distributor truck before sampling. Take samples from the distributor truck at mid -load or from a sampling tap or thief. Before taking samples, in the presence of the Engineer or representative, draw and dispose of 1 gal of asphaltic emulsion . In the presence of the Engineer , take four 1 -quart samples of asphalt emulsion in plastic containers with lined sealed lid for testing. Use 2-quart samples for QC testing and submit 2 -quart samples to the Engineer for acceptance testing. Sample must be submitted in insulated shipping container. For asphaltic emulsion, the authorized laboratory must perform quality control sampling and testing at each tanker load according to section s 94-1.02C or 94 -1.02E . 30-5.01D(2)(e)(i i)(D) Partial Depth Recycling Perform sampling and testing at the specified frequency and location for the following quality characteristics as shown in the following table : PDR Quality Testing Frequencies Quality characteristic Test method Minimum sampling and testing frequency Location of sampling Water sulfatesa (max, ppm) California Test 417 1 per source Source Water chloridesa (max, ppm) California Test 422 1 per source Source Asphalt expansion and half -life for PDR -FA Visual inspection Each tanker truck Recycling equipment Maximum wet gradation (% passing) Sieve size: AASHTO T 27 Test strip and 2 per lot Recycled mat SECTION 30 RECYCLED PAVEMENT 1-1/4" Wet gradation (% passing) Sieve size: 1-1/4" 1" 3/4" No. 4 AASHTO T 27 Test strip and every 3rd lot Dry gradationb (% passing) Sieve size : 1-1/4" 1" 3/4" No. 4 No. 30 No. 200 AASHTO T 27 1 per day and prior to the introduction of recycling agent Indirect dry tensile strength (psi) California Test 372 Every other lot Indirect wet tensile strength (min, psi)c California Test 372 Every other lot aOnly required for non -potable water sources. bSampling must be conducted prior to mixing the RAP with recycling agent and cement. cFabricate companion samples for Department testing. 30-5.01D(2)(e)( ii)(E) Density Take a sample of the loose PDR mixture daily on workdays when PDR operations are active at a location determined by the Engineer. Split the PDR sample into 2 parts and label each part with the location and station. Submit 1 split part and use 1 part for your testing. For density, perform sampling and testing at the specified frequency and location for the following quality characteristics as shown in the following table : Density Quality Testing Frequencies Quality characteristic Test method Minimum sampling and testing frequency Location of sampling In-place wet density (g/cc)a California Test 375
Part 4 — , or California
Test 231 Test strip and 1 per day Compacted mix Relative compactiona,b (min, %) California Test 375 or California Test 231 Test strip and 2 test sites per sub - lot Compacted mix aUse California Test 375 for 4 inches or less and California Test 231 for greater than 4 inches. The relative compaction is based on the break -over point. Verify break -over point once per day of production and when new rolling pattern is established. bTesting frequency is a minimum of 2 test sites per sub -lot and no lot must be represented by fewer than 5 test sites. 30-5.01D(2)(e)(i i)(F) Smoothness During cold -planing, use straightedge to record surface smoothness at least once every 1,000 feet along the cut length. Stop cold -planing activities and immediately notify the Engineer whenever:
1.Variance of more than 0. 02 foot measured from the lower edge of a 12 -foot straightedge placed parallel with the centerline
2.Transverse slope variance of more than 0.03 foot measured from the lower edge of a 12 -foot straightedge
3.Visual inspection shows evidence of : SECTION 30 RECYCLED PAVEMENT 3.1. Ravel ing 3.2. Loose material 3.3. Non-uniform surface texture After completing PDR activities, prior to HMA overlay, determine PDR surface smoothness under section 36-3. Smoothness is measured after supplemental compaction for PDR -EA and final compaction for PDR-FA. Correct PDR surface with MRI greater than 90 in/mi for each 0.1 -mile section and areas of localized roughness greater than 240 in/mi. Measure smoothness after corrections have been made under section 30-5.01C(10). Correct areas by grinding or micro milling, then reapply asphaltic emulsion and sand, before opening to public traffic. Smoothness corrections must leave at least 90 percent of the specified PDR thickness. Verify remaining PDR thickness based on section 30 -5.01D(3). Remove and replace defic ient pavement areas where the HMA overlay thickness is less than 75 percent of the thickness specified. 30-5.01D(3) Department Acceptance The Engineer samples materials for testing under California Test 125 PDR acceptance is based on:
1.Visual inspection for: 1.1. Segregation, raveling, rutting, humps, depressions, roller marks, and loose material . 1.2. Uniform surface texture throughout the work limits .
2.Compliance with smoothness requirements on the PDR surface of: 2.1. MRI of 90 in/mi or less for eac h 0.1 -mile section . 2.2. Areas of localized roughness no greater than 240 in/mi . 2.3. Areas that require PDR surface smoothness determined using a 12 -foot straightedge . The PDR surface must not vary from the lower edge of the straightedge by more than: 2.3.1 . 0.02 foot when the straightedge is laid parallel with the centerline 2.3.2 . 0.03 foot when the straight edge is laid perpendicular to the centerline and extends from edge to edge of a traffic lane
3.Asphalt acceptance is based on the Departme nt's sampling and testing for compliance with the requirements for the quality characteristic in section 92 table "PG Asphalt Binder " for the performance grade of asphalt used
4.Asphaltic emulsion acceptance is based on the Department 's sampling and testing for compliance with the requirements shown in the following table: Asphaltic Emulsion Requirements Quality characteristic Test method Requirements Minimum Maximum Test on emulsion: Sieve test (max, %) Residue by evaporation (min, %) AASTHO T 59 AASHTO T 59 -- 28.5a 0.1 -- Test on residue by evaporation: Penetration, at 25 °C (mm) AASHTO T 49 40 90 aResidue requirement is based on 1:1 dilution ratio of asphaltic emulsion and water.
5.Compliance with quality characteristic requirements in the following table: SECTION 30 RECYCLED PAVEMENT PDR Quality Quality characteristic Test method Requirement Maximum wet gradation (% passing) Sieve size: 1-1/4" AASHTO T 27 100 Wet gradation (% passing) Sieve size : 1-1/4" 1" 3/4" No. 4 AASHTO T 27 100 Report only Report only Dry gradation (% passing) Sieve size : 1-1/4" 1" 3/4" No. 4 No. 30 No. 200 AASHTO T 27 Report only Indirect wet tensile strength (min, psi) California Test 372 Report only Relative compaction (min, %)a California Test 231 or California Test 375 98–102 Thickness (inch )b: Each core Average thickness of cores Core measurements ±0.75 inch of the thickness shown ≥ thickness shown aThe a verage of lot test locations must be between 98 to 102 percent with no individual test less than 95 to 105 percent. Use California Test 375 for 4 inches or less of PDR thickness and California Test 231 for greater than 4 inches of PDR thickness . bTake 4 -or 6-inch core from one random location per lot as determined by the Engineer. Perform coring and measure core depth in the presence of the Engineer . If core retrieval is not achieved , you may submit depth measurements, taken in the presence of the Engineer . This process will be done after supplemental compaction for PDR -EA. Coring must be done after any smoothness corrections. If the Engineer orders you to stop PDR activities for noncompliance, before resuming activities:
1.Notify the Engineer of the adjustments you will make
2.Repr ocess, remedy, or replace the noncompliant lot
3.Obtain the Engineer's authorization 30-5.01D(4) Dispute Resolution The Engineer and you must work together to avoid potential conflicts and to resolve disputes regarding test result discrepancies. The Eng ineer and you may only dispute each other's test results if one party's test results pass and the other party's test results fail. If there is a dispute, submit your test results, documentation of visual inspections, quality control test results , and copie s of paperwork including worksheets used to determine the disputed test results to an ITP. Before the ITP participates in a dispute resolution, the ITP must be qualified under AASHTO re:source program and the Department's Independent Assurance Program. The ITP must have no prior direct involvement with this Contract. By mutual agreement between the Engineer and you , the ITP is chosen from one of the following :
1.Another Department laboratory located in the district or region where the project is not locate d
2.METS
3.Laboratory not currently employed by you or your PDR producer on this project If the split acceptance samples are not available, the ITP uses any available material agreed by the Engineer and you as representing the disputed PDR for evaluatio n. SECTION 30 RECYCLED PAVEMENT For a dispute involving the visual inspection, an academic subject matter expert may also perform a visual inspection jointly with the ITP, as specified in 30-5.01D(3). If the ITP determines the Department's test results are valid, the Engineer deducts the ITP's testing costs from payments. If the ITP determines your test results are valid, the Department pays the ITP's testing costs. 30-5.02 MATERIALS 30-5.02A General A summary of existing material investigations is available in the Information Handout as supplemental project information. 30-5.02B Material Quality Characteristics During Production Material quality characteristics during production must comply with the following requirements as shown in the following table : PDR Quality Characteristic Requirements Quality characteristic Test method Requirement Asphalt expansion and half -life for PDR -FA Visual inspection Foaming Maximum wet gradation (% passing) Sieve size : 1-1/4" AASHTO T 27 Wet gradation (% passing) Sieve size : 1-1/4" 1" 3/4" No. 4 AASHTO T 27 100 Report only Report only Dry gradation (% passing) Sieve size : 1-1/4" 1" 3/4" No. 4 No. 30 No. 200 AASHTO T 27 Report only Relative compaction (min, %)a California Test 231 or California Test 375 98–102 In-place wet density (g/cc) California Test 375,
Part 4 — Report only
Thickness (inch)b Each core Average thickness of cores Core measurements ±0.75 inch of the thickness shown ≥ thickness shown Indirect dry tensile strength (psi) California Test 372 Report only Indirect wet tensile strength (min, psi) California Test 372 Report only aThe a verage of lot test locations must be between 98 to 102 percent with no individual test less than 95 to 105 percent. Use California Test 375 for 4 inches or less and California Test 231 for greater than 4 inches. bCoring must be done after any smoothness correction. Take 4 -or 6-inch core from one ra ndom location per lot as determined by the Engineer. Coring at more than one location per lot is change order work. Perform coring and measure core depth in the presence of the Engineer . If core retrieval is not achieved , you may submit depth measurements, taken in the presence of the Engineer . This process will be done after supplemental compaction for PDR -EA. SECTION 30 RECYCLED PAVEMENT 30-5.02C Water Water source must be potable water . 30-5.02D Cement Reserved 30-5.02E Recycling Agent The recycling agent must be PG 64-10 unmodified binder for PDR -FA. Cationic emulsified recycling agent must comply with the requirements in section 94 -1.02E. 30-5.02F PDR Mix Design The mix design must include RAP from the job site, asphalt, cement, and w ater. The mix design must comply with California Test 315 and the requirements shown in the following table: Mix Design Requirements Quality characteristic Test method Requirement Maximum density (lb/cu ft) California Test 315 Report only Indirect dry tensile strength (psi) California Test 372 45 Indirect wet tensile strength (min, psi) California Test 372 31.5 Ratio of asphalt binder to cement (min, %) -- 2.5:1 Raveling test at 50 °F (max, %) ASTM D7196 7 RAP coating test for PDR EA (%) AASHTO T 59 95 Cement must be at least 0.50 but not more than 1.0 percent of the dry weight of In -place recycled pavement material. If coring indicates the original mix design is incorrect, then additional coring and mix designs will be a change orde r. 30-5.02G Temporary Structural Section The minor HMA for the temporary structural section must comply with section 39 -2.07. 30-5.02H Asphaltic Emulsion Asphaltic emulsion must comply with section 94 -1.02C or 94 -1.02E . 30-5.02I Sand Cover Sand used for sand cover must comply with the material specifications for fine aggregate in section 90 - 1.02C(3). Sand must not contain more than 2 percent moisture by dry weight of sand. 30-5.03 CONSTRUCTION 30-5.03A General Do not disturb or damage the underlying materials during pavement cold -planing activities. Do not use a heating device to soften the pavement. At all times maintain 20 tons of commercial quality asphaltic surfacing material onsite for maintenance and protection of the completed PDR surface. Use the same equipment, materials, rolling pattern , and construction methods that were used for the authorized test strip for the remainder of the PDR work. Obtain the Engineer 's authorization before any adjustments. If the equipment or process fails to meet the Department acceptance , stop PDR activities, and notify the Engineer. 30-5.03B Surface Preparation Before starting PDR activities, prepare the existing roadway by:
1.Removing loose material from the roadway including: 5 SECTION 30 RECYCLED PAVEMENT 1.1. Dirt 1.2. Vegetation 1.3. Standing water 1.4. Combustible materials 1.5. Oils 1.6. Pavement markers and underlying adhesive
2.Accurately referencing the existing pavement's profile and cross slope
3.Accurately marking the proposed longitudinal cut lines on the existing roadway surf ace 30-5.03C Partial Depth Recycling Equipment 30-5.03C(1) General Ensure t he equipment for PDR includes :
1.Cold-planing equipment
2.Mixing chamber or pugmill
3.Mixing and proportioning equipment
4.Water storage and supply equipment Cement storage, supply , and spreading equipment
6.PDR mixture spreading equipment
7.Compacting equipment 30-5.03C(2) Cold -Planing Equipment Provide cold-planing machine that:
1.Is self-propelled .
2.Has a 12-foot-wide minimum cutter that can recycle the exis ting pavement to the specified depths . You may use a cold-planing machine with a cutter narrower than 12 feet wide for shoulders and miscellaneous areas, in addition to the 12 -foot-wide minimum cutter .
3.Is equipped with automatic depth and cross slope co ntrols capable of maintaining the cutting depth to within 0.25 inch of the shown depth . You may provide t he cold -planing machine equipped with ski devices with conventional contact ski , noncontact laser , or sonar device for longitudinal profile. During pavement transitions or large grade breaks , skis may be lifted or turned off. If you use volumetric proportion systems, make sure the volume of the cut does not vary by more than 2 percent, or determine margin of error , unless metering systems for recycling agent and cement automatically adjust for variable volume during recycling process. 30-5.03C(3) Mixing Chamber or Pugmill Provide a continuous mixing chamber or pugmill mixing machine as part of the recycle train with ei ther a belt scale or an integrated microprocessor control system to control:
1.In-place recycled pavement material delivered to the mixing chamber or pugmill
2.Amount of recycling agent being delivered Arrange t he mixing chamber or pugmill to mix the in -place recycled pavement material, recycling agent, and cement to produce the specified PDR mixture. The mixing chamber may be equipped with paddles or other suitable mixing devices. If paddles or other suitable mixing devices are used , the in -place recycl ed pavement material must be fed from the pulverizing, crushing, or sizing equipment to the mixer at a uniform and controlled rate. The PDR machine must rear load directly into the paver 's receiving hopper or the paver 's loading equipment must pick up the PDR mixture and deposit it in the paving machine without waste. If the paving screed is directly attached to the PDR equipment, feed the PDR mixture directly to the paving screed. 30-5.03C(4) Mixing and Proportioning Equipment Use a mass flow, Coriolis Ef fect type meter with a visible readout display and printing capabilities. SECTION 30 RECYCLED PAVEMENT The weighing and measuring devices for the recycling agent and cement must comply with the requirements of the MPQP , section 4. You may use equipment that has successfully passed the calibration requirements of MPQP within the past 6 months. 30-5.03C(5) Water Storage and Supply Equipment Interlock the supplemental water equipment with the in -place recycled pavement material weighing device or microprocessor to properly disperse the r ecycling agent. 30-5.03C(6) Cement Storage, Supply, and Spreading Equipment Keep cement in dry cement spreader trucks, pneumatic trailers, or silos. Use an automated spreader capable of spreading the cement at the required weight per unit area. Provide t he spreader with working scales and distance measuring devices to verify the spread rate. 30-5.03C(7) Spreading Equipment Provide s preading equipment comply ing with section 39 -2.01C(2). Make sure s preading equipment is equipped with ski devices for longitudinal profile. The ski devices may be a conventional contact ski , noncontact laser , or sonar device. 30-5.03C(8) Compacting Equipment Provide c ompacting equipment comply ing with sections 39 -2.01C(2). Provide a minimum of 1 pneumatic - tired roller weighing at least 25 tons and 1 double drum vibratory steel -wheeled roller weighing at least 10 tons and at least 5.5 f eet wide. E nsure e ach roller ha s a working water spray system. 30-5.03D Partial Depth Recycling 30-5.03D(1) General Do not perform PDR activities under the following conditions:
1.Pavement surface is wet due to rain .
2.Rain is forecasted within 24 hours of the scheduled work .
3.Pavement temperature is less than 60 degrees F .
4.Ambient temperatur e is less than 50 degrees F .
5.Time is b etween 30 minutes before sunset and 30 minutes after sunrise for PDR -EA, without the Engineer 's authorization .
6.Freezing temperatures are forecasted with in 48 hours of the scheduled work . Use the existing pavemen t profile and cross slope to establish the PDR finished profile and cross slope. You may adjust the recycling depth by ± 0.75 inch from the depth shown to achieve uniform pavement profile, cross slope, and surface smoothness. Make sure t he average recycled depth determined by cores is equal to or greater than the depth shown. To achieve PDR surface smoothness requirements, you may use a cold -planer with automatic controls and sensors for profile control ; or, perform smoothness correction on the existing pav ement prior to performing PDR ; or use both methods . Follow the spreading and compacting requirements required for PDR paving. 30-5.03D(2) Cold -Planing Do not leave gaps of unrecycled material between successive cuts along the same longitudinal cut line. Do not leave untreated wedges created by the entry of the milling drum into the existing pavement. Overlap l ongitudinal joints a minimum of 4 inches between successive cuts. During cold -planing of existing pavement , use automatic controls for profile and cr oss slope . If cold -planer automatic controls for profile and cross slope are used for achieving smoothness, use ski devices for longitudinal profile. The ski devices may be conventional contact ski , noncontact laser , or sonar device. The cutting head neare st the centerline must be controlled by a sensor activated by a ski device not less than 20 feet long. The end of the cutting head farthest from centerline must be controlled by:
1.Sensor activated by a similar ski device if adjacent to a lane or paved sh oulder SECTION 30 RECYCLED PAVEMENT
2.Automatic transverse slope device set to reproduce the existing pavement cross slope if adjacent to an unpaved shoulder or no shoulder When cold -planing adjacent to previously completed PDR lanes , use automatic controls for profile and cross slo pe. The end of the cutting head adjacent to the PDR lane must be controlled by a sensor that responds to the grade of the previously completed PDR surface and will reproduce the grade within a 0.01-foot tolerance. The end of the cutting head farthest from the previously completed PDR surface must be controlled in the same way it was controlled during initial cold -planing. 30-5.03D(3) Unsuitable Conditions If you encounter unsuitable subgrade material:
1.Notify and meet with the Engineer immediately .
2.Clearly define the unsuitable material areas and depth .
3.Excavate and dispose of any unsuitable subgrade material encountered .
4.Backfill the excavated area with Class 2 AB as specified in section 26, or with PDR material which has been produced in the last 4 hours and is compliant with these specifications. Compact PDR material to 95 percent relative compaction based on break -over point.
5.Within 24 hours of defining unsuitable material , submit the following: 5.1. List of u nsuitable areas including station or postmile, length, width, depth, and centerline offset 5.2. Remediation taken, including quantities of materials used Place HMA Type A or a premixed asphaltic material equivalent in thickness to the existing asphalt concrete layer adjacent to the excavation on top of Class 2 AB. If premixed asphaltic material is used, remove and replace it with HMA Type A prior to placing final surfacing. Place HMA in layers and compact until the level of the PDR surface is reached. Excavating and disposing of unsuitable material and replacing with AB and surfacing material is change order work. 30-5.03D(4) Recycling Agent for PDR -FA Use PG 64-10 unmodified binder for PDR -FA. Do not use other PG grades without the Engineer 's authorization and meeting the mix design requirements in CT315. Inspect recycling agent foaming half -life and expansion ratio for each tanker load of asphalt. Verify the half-life and expansion ratio by visual inspection and confirm that the foaming action of the recycling agent is taking place through the test port. 30-5.03D(5) Cement Add cement into the recycling process by one of the following methods:
1.Add directly in the pugmill
2.Spread on the existing pavement surface ahead of the recycling train in a dry form If you spread cement directly onto the existing pavement, do not spread more than 50 feet ahead of the recycling train. Do not spread under windy conditions. Employ dust control measures to minimize fugitive dust. Do not allow spread cement to remain exposed at the end of the work shift. Do not allow traffic other than the recycling equipment to pass over the spread cement. 30-5.03D(6) Water Water added for c ompaction must be added by the recycling unit. If a water source other than potable water is used, test water for sulfates and chlorides to comply with the following requirements as shown in the following table: SECTION 30 RECYCLED PAVEMENT Water Requirements Quality characteristic Test method Requirement Water sulfates (max, ppm) California Test 417 1,300 Water chlorides (max, ppm) California Test 422 650 30-5.03D(7) Proportioning Verify t he amount of recycling agent match es the amount reported in the JMF or the amount as adjusted. Obtain the Engineer 's authorization before adjusting the recycling agent amount. 30-5.03D(8) Spreading and Compacting Remove any visible oversized crack treatment material or paving fabric larger than 1 inch measured at any dimension in the in -place recycled pavement material or in the PDR mixture before placement and compaction. When placing the initial mat of PDR, the end of the screed nearest the centerline must be controlled by a sensor activat ed by a ski device not less than 20 feet long. The end of the screed farthest from centerline must be controlled by:
1.Sensor activated by a similar ski device if adjacent to a lane or paved shoulder
2.Automatic transverse slope device set to reproduce t he existing pavement cross slope if adjacent to an unpaved shoulder or no shoulder When paving contiguously with previously placed PDR, the end of the screed adjacent to the previously placed PDR must be controlled by a sensor that responds to the grade o f the previously placed PDR surface and will reproduce the grade in the new PDR within a 0.01 -foot tolerance. The end of the screed farthest from centerline must be controlled by:
1.Sensor activated by a similar ski device if adjacent to a lane or paved s houlder
2.Automatic transverse slope device set to reproduce the existing pavement cross slope if adjacent to an unpaved shoulder or no shoulder You may vary the depth of the PDR to achieve uniform PDR pavement profile, cross slope, and surface smoothnes s. Do not allow segregation of PDR mixture . Do not allow tearing or scarring of the compacted surface. For PDR -EA, determine the time interval between spreading and start of compacting PDR mixture. Establish the time interval based on ambient temperatures, weather, and type of emulsified asphalt. Record the time intervals in the daily quality control records. Avoid starting or stopping rolling on uncompacted material. Compact the PDR mixture by implementing the same compaction rolling pattern established in the authorized test strip. Establish a new rolling pattern if any of the following occur:
1.Relative compaction of any of 10 individual locations is less than 95 or greater than 105 percent of the break -over point
2.Average relative compaction of the lot is less than 98 or greater than 102 percent of the break -over point
3.Changes in the in -place recycled pavement material or proportions
4.Changes in equipment or procedures
5.Change in temperature or weather conditions affecting mixing and compactio n temperatures of the placed mixture
6.Visible displacement or cracking occurs Perform final rolling with a double -drum vibratory steel -wheel roller operating in static or vibratory mode. Ensure t he compacted PDR surface is free from raveling, segregatio n, rutting, humps, depressions, roller marks, or irregularities. Rework, recompact, or remove and replace PDR that shows raveling, segregation, rutting, humps, depressions, roller marks, or irregularities. SECTION 30 RECYCLED PAVEMENT For PDR smoothness, verify the completed PDR surfa ce has an MRI of 90 in/mi or less for a 0.1 -mile section and no areas of localized roughness greater than 240 in/mi. For areas that require PDR surface smoothness determined using a 12 -foot straightedge, verify the PDR surface does not vary from the lower edge of the straightedge by more than:
1.0.02 foot when the straightedge is laid parallel with the centerline
2.0.03 foot when the straightedge is laid perpendicular to the centerline and extends from edge to edge of a traffic lane 30-5.03E Asphaltic E mulsion and Sand Cover Notify the Engineer if you dilute the asphaltic emulsion with water. Do not exceed t he ratio 1:1 by weight of added water to asphaltic emulsio n. Measure added water weight. After final compaction and before opening the PDR surface to traffic, apply a coat of asphaltic emulsion followed by sand cover to the PDR surface. Place temporary painted traffic stripes and painted pavement markings used for temporary delineation. Make sure t he application rate of asphaltic emulsion is from
0.13 to 0.25 gal/sq yd. Do not water after applying asphaltic emulsion.
Spread sand cover after asphaltic emulsion is applied under section 37 -4.03C. Apply temporary pavement delineation in accordance with section 12 -6. Remove excess sand from the pavement surf ace by sweeping before opening to traffic. 30-5.03F Temporary Structural Section Use minor HMA or commercial quality asphaltic material to construct a temporary structural section. Place a temporary structural section to the level of the PDR surface if:
1.You are unable to complete the PDR before opening to traffic
2.PDR fails during the maintaining period by raveling or rutting For minor HMA or commercial quality asphaltic material, place in layers and compact until the level of the PDR surface is reac hed. Compact the minor HMA or commercial quality asphaltic material using method compaction process as specified in section 39 -2.01C(15)(b). If commercial quality asphaltic material or minor HMA is used, remove and replace it with HMA Type A under an authorized JMF meeting the requirements for HMA Type A before placing overlay. 30-5.03G Maintain, Cure , and Protect Surface Do not recompact the PDR for PDR -FA. Do not place the HMA layer over PDR surface until one of the following conditions is met:
1.Three days and moisture measured at mid -depth of the PDR pavement is 2.0 percent or less
2.Ten days without rainfall
3.Four days without rainfall and no change in measured moisture content of the PDR pavement within a 24-hour period Immediately repair an y damage or defects before opening to traffic by:
1.Reworking and recompacting the PDR surface
2.Replacing any damaged area with the same depth of cold asphaltic surfacing material or HMA Place HMA layer within 15 days of completion and acceptance of th e PDR layer. Completion is defined as full acceptance of specification requirements by the Engineer, typically upon acceptance of PDR smoothness submittal after any smoothness corrections. 30-5.03H Supplemental Compaction for PDR -EA Recompact the PDR surf ace: SECTION 30 RECYCLED PAVEMENT
1.After curing is completed per section 30 -5.03G
2.When surface temperature is at least 80 degrees F
3.Before smoothness testing
4.Before placing the HMA surfacing Use the same equipment to establish the rolling pattern and break over curve for r ecompacting the PDR surface. Do not make adjustments without the Engineer 's authorization. 30-5.04 PAYMENT Test strips are paid for as PDR. The Department does not adjust the unit price for an increase or decrease in the quantity for the following PDR ite ms:
1.Cement
2.Recycling agent
3.Asphaltic emulsion
4.Sand cover 30-6–30-9 RESERVED 30-10 CRACK AND SEAT 30-10.01 GENERAL 30-10.01A Summary Section 30 -10 includes specifications for constructing a base by cracking, seating, and preparing the surface of existing concrete pavement . 30-10.01B Definitions Reserved 30-10.01C Submittals Submit each core in a plastic bag or tube for authorization at the time of sampling. Mark each core with a location description . 30-10.01D Quality Assurance 30-10.01D(1) General If cracking is noncompliant:
1.Stop crack and seat work
2.Modify your equipment and procedures and crack the noncomplian t pavement again
3.Construct another test section
4.Take additional core samples to verify compliance
5.Construct an inspection strip if the concrete pavement has HMA on the surface 30-10.01D(2) Test Section The Engineer determines and marks a test se ction up to 1 ,000 sq ft within the crack and seat area shown. Construct the test section and obtain the Engineer's verbal authorization before starting crack and seat work. Immediately before cracking the test section, apply water to the pavement surface s o that cracking can be readily evaluated. Crack the test section and vary impact energy and striking patterns to verify your procedure. 30-10.01D(3) Quality Control Drill cores at least 6 inches in diameter under ASTM C42 to verify cracking in the Engineer 's presence. Take at least 2 cores per test section and 1 core per lane mile for each pavement cracking machine used. The Engineer determines the core locations. SECTION 30 RECYCLED PAVEMENT 30-10.01D(4) Department Acceptance Reserved 30-10.02 MATERIALS 30-10.02A General Use fast -setting or polyester concrete to fill core holes. 30-10.03 CONSTRUCTION 30-10.03A General Reserved 30-10.03B Cracking Crack existing concrete pavement using the procedures and equipment from the aut horized test section. Do not allow flying debris during cracking operations. Crack existing concrete pavement into segments that nominally measure 6 feet transversely by 4 feet longitudinally. If the existing pavement is already cracked into segments, crac k it into equal -sized square or rectangular pieces that nominally measure not more than 6 feet transversely and from 3 to 5 feet longitudinally. Do not impact the pavement within 1 foot of another break line, pavement joint, or edge of pavement. Cracks mus t be vertical, continuous, and penetrate the full depth of pavement. Cracks must be within 6 inches of vertical along the full depth of pavement. Do not cause surface spalling over 0.10 -foot deep or excessive shattering of the pavement or base. Cracking eq uipment must impact the pavement with a variable force in a controlled location. Do not use unguided free -falling weights such as "headache balls." If the concrete pavement has no more than 0.10 foot of asphalt concrete on the surface, you may crack the pa vement without removing the asphalt concrete. After cracking, construct an inspection strip by removing at least 500 square feet of asphalt concrete at a location determined by the Engineer. Construct additional inspection strips to demonstrate compliance where ordered by the Engineer. After cracking, allow public traffic on the cracked or initial pavement layer for no more than 15 days. 30-10.03C Seating Seat cracked concrete by making at least 5 passes over the cracked concrete with either:
1.Oscillating type pneumatic -tired roller at least 4 feet wide. Pneumatic tires must be of equal size, diameter, type, and ply. The tires must be inflated to 60 psi minimum and maintained so that the air pressure does not vary more than 5 psi. The roller's gross static weight must be at least 15 tons.
2.Vibratory pad -foot roller exerting a dynamic centrifugal force of at least 10 tons. A pass is 1 movement of a roller in either direction at 5 mph or less. After all segme nts have been seated, clean loose debris from joints and cracks using compressed air free of moisture and oil. Reseat any segment of cracked pavement that has not been overlaid within 24 hours of seating. 30-10.03D Surface Preparation Before opening cracked and seated pavement to traffic or overlaying:
1.Fill joints, cracks, and spalls wider than 3/4 inch and deeper than 1 inch by applying tack coat and placing minor HMA under sect ion 39, except use the no. 4 gradation instead of 3/8 -inch
2.Remove all loose debris and sweep the pavement SECTION 30 RECYCLED PAVEMENT 30-10.03E Reserved 30-10.04 PAYMENT The payment quantity for crack and seat is the area measured with no deductions for existing cracked segment s. 31–35 RESERVED
Source: California Standard Specifications, 2024 Edition. Pages 443–480 of 1,372.